MAGCO INC. OF Jessup, Md., was founded in July 1987 by Mark Gaulin to be a leader in the installation and maintenance of industrial-, commercial- and green-roof systems. In February 2000, it became a founding member of Skokie, Ill.-based Tecta America Corp., which united some of the highest quality roofing installers across America. Today, Magco still strives to be a leader in the installation, reroofing and preventative maintenance of nearly all types of industrial and commercial roof systems. The company handles projects ranging from leaks to major renovations and new construction in the Baltimore and Washington, D.C., areas, as well as Delaware, Pennsylvania and northern Virginia. Being a niche business, Magco takes a special interest in solar installations with metal roofing and green roofing. So when Magco built a new facility for itself in 2003, Gaulin saw a perfect opportunity to show what his business is all about. “Tecta has always been a leader in environmental initiatives, and we decided to use this project as a showpiece for many of the environmental solutions we offer,” states Gaulin, now chief operating officer of Tecta America. The building began with a metal frame and unpainted Galvalume steel structural standing-seam roof with a 3-inch (76-mm) trapezoidal seam. A sloped awning draws attention to the entrance. Although metal naturally is a green material because of its durability and recyclability, Magco knew it wasn’t enough to show the options available to someone thinking about constructing or retrofitting a building to be green. As the founder of a roofing company, Gaulin focused on the building’s roof.

HERE COMES THE SUN

Magco’s building sits on a small hill without any shade. Its 22,000-squarefoot (1980-m2) metal roof with a 1:12 (5- degree) slope is the perfect platform for solar panels. Rather than selecting more traditional crystalline panels, Magco opted to go with thin-film photovoltaic panels. It is a triple-junction laminate panel, meaning the PV chemicals are laminated to a thin sheet of metal in three layers. The layers each react to a different light range. A sealant protects the panels, making them low maintenance. The PV laminates are rolled out onto the roof surface and glued down; penetrations that can void the roof warranty are not required. PV laminates also are lightweight and don’t need supports. “We feel that thin-film and building integrated PV will be the future of solar and it is very adaptable to metal roofing,” says Patrick Bollinger, project manager at Magco. Before installing the solar panels, Magco prepared the roof by power washing it. Then, to provide a level surface, the recessed stiffening rib in the center of the metal roof panels was filled with strips of self-adhering bitumen roof membrane.

Magco outsourced the electrical work to make the panels functional. An electrical combiner box and power inverter were installed to work with the building’s electrical system. A two-way power meter flows any excess power generated by the solar panels into the power grid. After the new meters are installed, Magco will receive money from the utility company for the excess power on the weekends when the building is unoccupied. During the regular work week, the power generated reduces peak energy loads. The PV laminates were connected with wires using weatherproof quick-connect ends that snap together, making installation easier. PVC wire raceways protect the wires between panels and are the only roof-mounted components in this 27- kilowatt system. Approximately 4,900 square feet (455 m2) of solar panels was installed on this project. Each of the 204 panels can, under optimum conditions, produce up to 136 watts of electricity per hour. The sun not only is producing electricity, it’s helping Magco save it. The company installed 30 light tubes to bring natural lighting into the warehouse. These tubes reflect and refract nearly 98 percent of the collected sunlight into the building. “Our tubes will also be connected to new, energy-efficient, light-sensing T8 fluorescent light fixtures that will have a combination of light- and motion-sensing features,” explains Bollinger. “The lights will turn on or off depending on activity in our warehouse, as well as the amount of sunlight being reflected into the building on a given day.”

AN ACTUAL GREEN ROOF

The 10- by 30-foot (3- by 9-m) entrance awning also was made green. A vegetated roof system consisting of succulent plants and drought-tolerant perennials was planted on this area. A perforated plastic soil stabilizer was incorporated to hold soil until the plants covered the surface. Installing this small roof was tricky because of worker safety concerns and the difficult accessibility of the awning. Plant coverage took nearly one year. Rainwater, which is used to water the awning, is beneficial to the green operations of the Magco facility. Water drains from the roof to two gutters and three downspouts and is collected in six 55- gallon (309-L) drums where it is stored until crews use it to clean trucks every Friday. Depending on the amount of rainfall, the water occasionally has to be supplemented with tap water. Rainwater also is used to irrigate the green-roof plants in Magco’s greenhouse; Magco grows the plants for other vegetated- roof projects and performs soil and product testing. Angie Durhman, Magco’s green-roof manager, states, “Based on 40 weeks in a given year, excluding cold weather months, we collect and recycle approximately 24,000 gallons (90850 L) annually.”

GREEN: THE COLOR OF MONEY

The Magco roofing project was completed in stages during the past two years. Its total cost was $270,000, with $215,000 of that being related to the PV laminates. Magco also expects to receive a year-end tax rebate. Magco currently is saving nearly one third on its electric bill each month. At the August 2008 electricity rate, Magco is anticipating producing $9,000 worth of electricity annually. Since the PV system was commissioned in June 2008, Magco also has saved 22,000 pounds (9979 kg) of greenhouse gasses. For more information about Magco’s energy production, visit www.pvpowered.com/AGT_TectaSolar. “By learning firsthand about the design, installation and real-world efficiency rates, we’ve been able to better assess our true costs and expectations,” Durhman says. “Our other sister Tecta America companies across the country are installing environmental features [on their buildings] for similar reasons.”

Krista Hovis writes about architecture and metal construction from Kansas, Ohio.

MAGCO HEADQUARTERS, JESSUP, MD.

METAL BUILDING AND ROOFING MANUFACTURER Southern Steel Buildings Inc., Gainesville, Ga., (678) 687-2430

METAL BUILDING ERECTOR, ROOF INSTALLER AND SOLAR PANEL INSTALLER Magco, Jessup, Md., www.magco.com

LIGHT TUBES Orion Energy Systems, Manitowoc, Wis., www.oriones.com

PHOTOVOLTAIC LAMINATES United Solar Ovonic, Auburn Hills, Mich., www.uni-solar.com